Systems and methods for coupling input/output devices

ABSTRACT

An input/output (I/O) device for an automation control system includes a base portion configured to communicatively connect the I/O device with at least one other I/O device, an I/O module physically and communicatively connected to the base portion and comprising I/O communication circuitry, a terminal block physically and communicatively connected to the base portion, and an ejection device configured to eject the I/O module or the terminal block from the base portion by pushing the I/O module or the terminal block out of engagement with the base portion when activated.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 13/214,027, filed Aug. 19, 2011, and entitled“Systems and Methods for Coupling Input/Output Devices,” which claimspriority of U.S. Provisional Patent Application No. 61/375,587, filedAug. 20, 2010, which are each herein incorporated in their entirety byreference.

BACKGROUND

The invention relates generally to the field of automation controlsystems, such as those used in industrial and commercial settings. Moreparticularly, embodiments of the present invention relate to techniquesfor providing, accessing, configuring, operating, or interfacing withinput/output (I/O) devices that are configured for coupling andinteraction with an automation controller.

Automation controllers are special purpose computers used forcontrolling industrial automation and the like. Under the direction ofstored programs, a processor of the automation controller examines aseries of inputs (e.g., electrical input signals to the automationcontroller) reflecting the status of a controlled process and changesoutputs (e.g., electrical output signals from the automation controller)based on analysis and logic for affecting control of the controlledprocess. The stored control programs may be continuously executed in aseries of execution cycles, executed periodically, or executed based onevents. The inputs received by the automation controller from thecontrolled process and the outputs transmitted by the automationcontroller to the controlled process are normally passed through one ormore I/O devices, which are components of an automation control systemthat serve as an electrical interface between the automation controllerand the controlled process.

Traditional I/O devices typically include a base configured to couplethe I/O device with a bus bar, communication bus, or the like, aterminal block for communicatively coupling the I/O device with fielddevices, and an I/O module that includes circuitry for performingcommunication functions and/or logic operations. In traditionalautomation control systems, the terminal block may be coupled to thebase by pushing the terminal block toward the base. Friction or a simplelocking mechanism between parts of the terminal block and the base mayhelp prevent the terminal block from disengaging from the base. Theterminal block may be removed from the base by pulling the terminalblock away from the base. It is now recognized that it is desirable toprovide more efficient and effective techniques for coupling, locking,and uncoupling terminal blocks from bases of I/O devices.

BRIEF DESCRIPTION

In one embodiment, an input/output (I/O) device for an automationcontrol system includes a base portion configured to communicativelyconnect the I/O device with at least one other I/O device, an I/O modulephysically and communicatively connected to the base portion andcomprising I/O communication circuitry, a terminal block physically andcommunicatively connected to the base portion, and an ejection deviceconfigured to eject the I/O module or the terminal block from the baseportion by pushing the I/O module or the terminal block out ofengagement with the base portion when activated.

In another embodiment, a component of an input/output (I/O) deviceincludes a first connector configured to engage with a second connectorof an additional component of the I/O device and an ejection deviceconfigured to eject the component from the additional component bydisengaging the connector from the second connector. The ejection deviceincludes a plunger configured to contact the additional component and alatch mechanism coupled to the plunger and configured to move thecomponent away from the additional component when the latch mechanism isactivated.

In yet another embodiment, a method for coupling and ejecting acomponent from a base portion of an input/output (I/O) device includesmoving the component toward the base portion in a first movement,coupling the component with the base portion, engaging the componentwith an ejection device disposed in the base portion, activating theejection device, and moving the component away from the base portionusing the ejection device.

DRAWINGS

These and other features, aspects, and advantages of the presentinvention will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 is a diagrammatical representation of an exemplary control andmonitoring system adapted to interface with networked components andconfiguration equipment in accordance with embodiments of the presenttechniques;

FIG. 2 is a perspective view of a plurality of I/O devices connected toan I/O adapter in accordance with embodiments of the present techniques;

FIG. 3 is an exploded perspective view of an exemplary I/O device thatincludes an ejection device in accordance with embodiments of thepresent techniques;

FIG. 4 is a partial side cross-sectional view of an exemplary I/O deviceincluding an ejection device and locking mechanism in accordance withembodiments of the present techniques;

FIG. 5 is a side cross-sectional view of an exemplary I/O deviceincluding a terminal block positioned above a base that includes anejection device in accordance with embodiments of the presenttechniques;

FIG. 6 is a side cross-sectional view of an exemplary I/O deviceincluding a terminal block adjacent to a base that includes an ejectiondevice in accordance with embodiments of the present techniques;

FIG. 7 is a side cross-sectional view of an exemplary I/O deviceincluding a terminal block coupled to a base that includes an ejectiondevice in accordance with embodiments of the present techniques;

FIG. 8 is a side cross-sectional view of an exemplary I/O deviceincluding a terminal block coupled to a base that includes an ejectiondevice with an activation mechanism in accordance with embodiments ofthe present techniques;

FIG. 9 is a side cross-sectional view of an exemplary I/O deviceincluding a terminal block positioned above a base that includes anejection device with an activation mechanism in accordance withembodiments of the present techniques;

FIG. 10 is a side cross-sectional view of an exemplary I/O device thatincludes a locking mechanism in an unlocked position in accordance withembodiments of the present techniques;

FIG. 11 is a side cross-sectional view of an exemplary I/O device thatincludes a locking mechanism in a locked position in accordance withembodiments of the present techniques;

FIG. 12 is a side cross-sectional view of an exemplary I/O device thatincludes a rotating locking mechanism in accordance with embodiments ofthe present techniques;

FIG. 13 is a cross-sectional view of an exemplary locking mechanism inan electrically conducting position in accordance with embodiments ofthe present techniques;

FIG. 14 is a cross-sectional view of an exemplary locking mechanism inan electrically non-conducting position in accordance with embodimentsof the present techniques; and

FIG. 15 is a flow chart of a process for operating an ejection device ofan exemplary I/O device in accordance with an embodiment of the presenttechnique.

DETAILED DESCRIPTION

While the present disclosure may be susceptible to various modificationsand alternative forms, specific embodiments have been shown by way ofexample in the drawings and tables and have been described in detailherein. However, it should be understood that the embodiments are notintended to be limited to the particular forms disclosed. Rather, thedisclosure is to cover all modifications, equivalents, and alternativesfalling within the spirit and scope of the disclosure as defined by thefollowing appended claims. Further, although individual embodiments arediscussed herein to simplify explanation, the disclosure is intended tocover all combinations of these embodiments.

FIG. 1 is a diagrammatical representation of an exemplary control andmonitoring system adapted to interface with networked components andconfiguration equipment in accordance with embodiments of the presenttechniques. The control and monitoring system is generally indicated byreference numeral 10. Specifically, the control and monitoring system 10is illustrated as including a human machine interface (HMI) 12 and anautomation controller or control/monitoring device 14 adapted tointerface with components of a process 16. It should be noted that suchan interface in accordance with embodiments of the present techniquesmay be facilitated by the use of certain network strategies. Indeed, anindustry standard network may be employed, such as DeviceNet, to enabledata transfer. Such networks permit the exchange of data in accordancewith a predefined protocol, and may provide power for operation ofnetworked elements.

The process 16 may take many forms and include devices for accomplishingmany different and varied purposes. For example, the process 16 maycomprise a compressor station, an oil refinery, a batch operation formaking food items, a mechanized assembly line, and so forth.Accordingly, the process 16 may comprise a variety of operationalcomponents, such as electric motors, valves, actuators, temperatureelements, pressure sensors, or a myriad of manufacturing, processing,material handling, and other applications. Further, the process 16 maycomprise control and monitoring equipment for regulating processvariables through automation and/or observation.

For example, the illustrated process 16 comprises sensors 18 andactuators 20. The sensors 18 may comprise any number of devices adaptedto provide information regarding process conditions. The actuators 20may include any number of devices adapted to perform a mechanical actionin response to a signal from a controller (e.g., an automationcontroller). The sensors 18 and actuators 20 may be utilized to operateprocess equipment. Indeed, they may be utilized within process loopsthat are monitored and controlled by the control/monitoring device 14and/or the HMI 12. Such a process loop may be activated based on processinputs (e.g., input from a sensor 18) or direct operator input receivedthrough the HMI 12.

As illustrated, the sensors 18 and actuators 20 are in communicationwith the control/monitoring device 14 and may be assigned a particularaddress in the control/monitoring device 14 that is accessible by theHMI 12. As illustrated, the sensors 18 and actuators 20 may communicatewith the control/monitoring device 14 via one or more I/O devices 22coupled to the control/monitoring device 14. The I/O devices 22 maytransfer input and output signals between the control/monitoring device14 and the controlled process 16. The I/O devices 22 may be integratedwith the control/monitoring device 14, or may be added or removed viaexpansion slots, bays or other suitable mechanisms. For example, asdescribed in greater detail below, additional I/O devices 22 may beadded to add functionality to the control/monitoring device 14. Indeed,if new sensors 18 or actuators 20 are added to control the process 16,additional I/O devices 22 may be added to accommodate and incorporatethe new features functionally with the control/monitoring device 14. TheI/O devices 22 serve as an electrical interface to thecontrol/monitoring device 14 and may be located proximate or remote fromthe control/monitoring device 14, including remote network interfaces toassociated systems. Further, the I/O devices 22 include multiplecomponents that couple together in accordance with present techniquesand features that facilitate decoupling.

The I/O devices 22 may include input modules that receive signals frominput devices such as photo-sensors and proximity switches, outputmodules that use output signals to energize relays or to start motors,and bidirectional I/O modules, such as motion control modules which candirect motion devices and receive position or speed feedback. In someembodiments, the I/O devices 22 may convert between AC and DC analogsignals used by devices on a controlled machine or process and DC logicsignals used by the control/monitoring device 14. Additionally, some ofthe I/O devices 22 may provide digital signals to digital I/O devicesand receive digital signals from digital I/O devices. Further, in someembodiments, the I/O devices 22 that are used to control machine devicesor process control devices may include local microcomputing capabilityon an I/O module of the I/O devices 22. In addition, the I/O devices 22may include several components configured to be coupled together, asdescribed in greater detail below. In various embodiments, the I/Odevices 22 may include mechanisms to enable the components to becoupled, ejected, locked, and/or uncoupled from one another.

In some embodiments, the I/O devices 22 may be located in closeproximity to a portion of the control equipment, and away from theremainder of the control/monitoring device 14. In such embodiments, datamay be communicated with remote modules over a common communicationlink, or network, wherein modules on the network communicate via astandard communications protocol. Many industrial controllers cancommunicate via network technologies such as Ethernet (e.g., IEEE802.3,TCP/IP, UDP, EtherNet/IP, and so forth), ControlNet, DeviceNet or othernetwork protocols (Foundation Fieldbus (H1 and Fast Ethernet) ModbusTCP, Profibus) and also communicate to higher level computing systems.

FIG. 2 is a perspective view of a plurality of I/O devices 22 connectedto an I/O adapter 24 in accordance with embodiments of the presenttechniques. The I/O adapter 24 is configured to provide system power tothe I/O modules 22, as well as to enable conversion between thecommunications protocols of the I/O devices 22 and thecontrol/monitoring device 14. As illustrated, the I/O adapter 24 and theplurality of I/O devices 22 are mounted to a DIN rail 26, which is anindustry standard support rail for mounting control equipment in racksand cabinets. As described in greater detail below, the plurality of I/Odevices 22 are electrically coupled in series along the DIN rail 26 suchthat field power and system information and power may be communicatedbetween the I/O devices 22, and back through the I/O adapter 24 to thecontrol/monitoring device 14. In other embodiments, the DIN rail 26 maybe replaced with a different type of mounting structure.

As also described in greater detail below, each of the I/O devices 22includes a base 28 for physically and communicatively connecting the I/Odevice 22 to the DIN rail 26, the I/O adapter 24 and/or adjacent I/Odevices 22, a terminal block 30, and one or more I/O modules 32. Theterminal block 30 may be used to electrically connect the I/O device 22to field devices, such as the sensors 18 and actuators 20 illustrated inFIG. 1. In certain embodiments, the terminal block 30 may be removablefrom the base 28. The I/O modules 32 may include I/O control circuitryand/or logic. In general, the I/O modules 32 receive input signals fromthe field devices, deliver output signals to the field devices, performgeneral and/or specific local functionality on the inputs and/oroutputs, communicate the inputs and/or outputs to the control/monitoringdevice 14 and/or the other I/O devices 22, and so forth. In addition,one or more of the I/O devices 22 includes an ejection device 80 tofacilitate ejection of the terminal block 30 and/or I/O module 32 fromthe base 28, as described in detailed below. For example, the ejectiondevice 80 may be configured to eject the terminal block 30 or the I/Omodule 32 from the base 28 by pushing the terminal block 30 or the I/Omodule 32 out of engagement with the base 28. It should be noted thatthe ejection device 80 may also be configured to facilitate coupling ofthe terminal block 30 or I/O module 32 to the base 28. In oneembodiment, the ejection device 80 engages with the base 28 and theterminal block 30 or I/O module 32 upon coupling of the two componentsand the act of coupling positions the ejection device 80 for activation.In some embodiments, each of the I/O devices 22 may include a lockingmechanism 140 to lock the terminal block 30 or the I/O module 32 to thebase 28, as described in detailed below. It should be noted that thelocking mechanism 140 may also be configured to facilitate uncoupling ofthe base 28 and the terminal block 30 or I/O module 32. In oneembodiment, the locking mechanism 140 couples the terminal block 30 orthe I/O module 32 to the base 28 when in a first position andfacilitates the release or ejection of the terminal block 30 or I/Omodule 32 from the base 28 when in a second position. In furtherembodiments, the I/O devices 22 may include both the ejection device 80and the locking mechanism 140.

FIG. 3 is an exploded perspective view of an exemplary I/O device 22with the ejection device 80 and/or the locking mechanism 140 inaccordance with embodiments of the present techniques. In the embodimentillustrated in FIG. 3, the terminal block 30 is a removable terminalblock that may be physically connected and electrically coupled to thebase 28 during assembly of the I/O device 22, and physicallydisconnected and electrically decoupled during disassembly (e.g., forservicing) of the I/O device 22. The removable nature of the illustratedterminal block 30 enables replacement of the I/O module 32 without theneed for re-wiring.

As illustrated, the terminal block 30 includes eight terminals 34 (i.e.,channels) for connecting field device wiring to the terminal block 30.Each of the terminals 34 is configured to be associated with aparticular input to or output from a field device. As illustrated, eachterminal 34 includes a terminal opening 36 into which a field wireelectrically connected to a field device may be inserted, and anattachment activator (e.g., a terminal screw) 38, which when activated(e.g., tightened) causes a clamp or other electrical wiring connectionmechanism within the terminal block 30 to tighten around an end of afield wire that has been inserted into the associated terminal opening36. As illustrated, each of the terminals 34 terminates at the bottom ofthe terminal block 30 with a terminal block connector 40, which may beinserted into terminal block connector openings 42 in the top of aterminal block bay 44 of the base 28 to physically and communicativelyconnect the terminal block 30 with the base 28. In the illustratedembodiment, each of the terminal block connectors 40 includes twoopposing electrical prongs 46 that slide around and electrically connectwith a single electrical prong (not shown) in the respective terminalblock connector opening 42 of the terminal block bay 44 of the base 28.However, in other embodiments, other types of terminal block connectors40 may be used to electrically connect with mating electrical connectorsin the respective terminal block connector opening 42 of the terminalblock bay 44 of the base 28.

The I/O module 32 may also be physically and communicatively connectedto the base 28 by inserting the I/O module 32 into a mating slot 48 inan I/O module bay 50 of the base 28. When the I/O module 32 is insertedinto the slot 48 in the I/O module bay 50 of the base 28, the I/O module32 becomes electrically coupled to the terminals 34 of the terminalblock 30 via internal circuitry within the base 28 that electricallyconnects the electrical prongs (or other suitable electrical connectors)in the terminal block connector openings 42 to respective electricaloutlets 52 in the top of the I/O module bay 50 of the base 28. Theelectrical outlets 52 for each channel are in turn electrically coupledto the I/O module 32 via respective electrical connectors (not shown)that, in certain embodiments, extend from the bottom of the I/O module32. As such, the terminal block 30, the base 28, and the I/O module 32are all electrically and communicatively coupled together such thatsignals to and from the field device to which the I/O device 22 isconnected are shared between the terminal block 30, the base 28, and theI/O module 32.

In addition, the I/O device 22 may also be electrically coupled to anI/O adapter 24 electrically upstream and/or other I/O devices 22electrically upstream or electrically downstream via electrical couplingfeatures of the I/O device 22. In certain embodiments, components thatare coupled electrically upstream of the I/O device 22 are componentsthat are on a left side 54 of the I/O device 22 when viewing the I/Odevice 22 from the front, and components that are electrically coupleddownstream of the I/O device 22 are components that are on a right side56 of the I/O device 22 when viewing the I/O device 22 from the front.However, in other embodiments, the upstream and downstream electricalcoupling features may be configured differently.

In certain embodiments, adjacent I/O devices 22 may be physicallyattached to each other via one or more connection features (e.g., slots)58 of the base 28 on one of the sides (e.g., the left side 54 of theillustrated embodiment) of the I/O device 22 near the bottom of the base28. Mating connection features such as protrusions (not shown) on theopposite side (e.g., the right side 56 of the illustrated embodiment) ofthe base 28 of the I/O device 22 near the bottom of the base 28. Incertain embodiments, connection features of an I/O device 22 may slideinto mating connection features of an adjacent I/O device 22, therebyphysically attaching the adjacent I/O devices 22.

When adjacent I/O devices 22 are physically attached to each other,system electrical contacts 60 on the base 28 on one of the sides (e.g.,the left side 54 of the illustrated embodiment) align with and areelectrically coupled to mating electrical contacts (not shown) on thebase 28 on the opposite side (e.g., the right side 56 of the illustratedembodiment) of an adjacent I/O device 22. Similarly, field electricalcontacts 62 on the base 28 on one of the sides (e.g., the left side 54of the illustrated embodiment) align with and are electrically coupledto mating electrical contacts (not shown) on the base 28 on the oppositeside (e.g., the right side 56 of the illustrated embodiment) of anadjacent I/O device 22. In the illustrated embodiment, the I/O device 22includes five system electrical contacts 60 and two field electricalcontacts 62. In such an embodiment, system power may be electricallycommunicated via electrically connected I/O devices 22 and/or the I/Oadapter 24 via two of the system electrical contacts 60, while the threeother system electrical contacts 60 are used for transmission of data(e.g., relating to signals transmitted to and from the field devices towhich the I/O devices 22 are electrically connected) between theelectrically connected I/O devices 22 and the I/O adapter 24. Inaddition, the two field electrical contacts 62 are used to electricallycommunicate power to the field devices to which the I/O devices 22 areelectrically connected. However, it will be understood that the specificnumber of system electrical contacts 60 and field electrical contacts 62may vary between implementations depending on the requirements for powerand data transmission of the I/O devices 22.

As illustrated, in certain embodiments, the I/O module 32 may include astatus display 64 on the top face of the I/O module 32 for displayingoperating status information of the I/O module 32, the base 28, and theterminal block 30. The status display 64 may, for example, includestatus light emitting diodes (LEDs) corresponding to each of theterminals 34 of the terminal block 30. Further, in certain embodiments,once the terminal block 30 and the I/O module 32 are physically andcommunicatively connected to the base 28 of the I/O device 22, a latch66 or other fastening device extending from the terminal block 30 mayfurther attach the terminal block 30 to the I/O module 32, therebyproviding additional structural support and stabilizing the electricalconnections between the terminal block 30, the I/O module 32, and thebase 28.

FIG. 4 is a partial side cross-sectional view of the I/O device 22 withthe ejection device 80 and locking mechanism 140 in accordance withembodiments of the present techniques. As shown in FIG. 4, pushing theejection device 80 may cause the terminal block connector 40 of theterminal block 30 to become disengaged from the terminal block connectoropening 42 of the base 28. Thus, the terminal block 30 may be ejectedfrom the base 28 using the ejection device 80. By using the ejectiondevice 80, the terminal block 30 may be removed from the base 28 withoutgrasping the terminal block 30 or the wires connected to the terminalblock 30. Therefore, the ejection device 80 may facilitate removal ofthe terminal block 30 from the base 28. In addition, the ejection device80 may be repositioned and used to facilitate removal of the module 32or other components of the I/O device 22. Further, the ejection device80 may be disposed in the base 28, the terminal block 30, the module 32,or in other components of the I/O device 22. Various embodiments of theejection device 80 and their operation are described in more detailbelow. In the illustrated embodiment, the locking mechanism 140 mayblock removal of the terminal block 30 from the base 28. Thus, thelocking mechanism 140 may help prevent inadvertent removal of theterminal block 30. The locking mechanism 140 may be moved or pushed outof the way when removal of the terminal block 30 is desired. Forexample, the locking mechanism 140 may be flexible to enable suchmovement. In further embodiments, the locking mechanism 140 may be usedto block removal of the module 32 or other components of the I/O device22. Various embodiments of the locking mechanism 140 and their operationare described in more detail below.

FIG. 5 is side cross-sectional view of an exemplary I/O device 22 inaccordance with embodiments of the present techniques. Specifically, theterminal block 30 is shown positioned above the base 28 prior to beingcoupled to the base 28. As illustrated, the base 28 includes theejection device 80. Specifically, the ejection device 80 may include apassage 82 formed in the base 28 along with other features. In certainembodiments, the passage 82 may have a circular cross-sectional shape, asquare cross-sectional shape, or any other cross-sectional shape. Theejection device 80 may include components secured in the passage 82using various methods, such as, but not limited to, adhesives, friction,threaded connections, screwed connections, bolted connections, and soforth. The ejection device 80 may include a plunger 84, which isconfigured to contact the terminal block 30. In certain embodiments, theplunger 84 may have a circular cross-sectional shape, a squarecross-sectional shape, or any other cross-sectional shape. In addition,the plunger 84 may have a diameter 85 less than a diameter 83 of thepassage 82. In other embodiments, the diameter 85 of the plunger 84 maybe approximately the same as the diameter 83 of the passage 82. As shownin FIG. 5, an exposed portion 86 of the plunger 84 (i.e., a portionoutside of the base 28) extends above a top surface 87 of the base 28when in an ejected mode. The ejection device 80 also includes a latchmechanism 88 and a biasing element 90, which together may determine theejection characteristics of the ejection device 80. For example, incertain embodiments, the latch mechanism 88 may be configured as apush-push latch mechanism, which may be defined as a latch mechanismthat performs a two step operation in which a first step includesengaging a first component with a second component when the first orsecond component is pushed in a direction, and a second step includesdisengaging or releasing the first component from the second componentwhen the first or second component is pushed in the same direction. Forexample, the push-push latch mechanism may be similar to that used withcertain ballpoint pens, and the biasing element 90 may be a spring orother mechanical deflection mechanism. Specifically, the latch mechanism88 may include cams and/or latches that enable the latch mechanism 88 tooperate in a manner described in detail below. Although shown separatelyin FIG. 5, in certain embodiments, the biasing element 90 may beintegral with or internal to the latch mechanism 88. In addition,although shown being used with the terminal block 30 in FIG. 5, in otherembodiments, the ejection device 80 may also be used with the module 32.

As shown in FIG. 5, in certain embodiments, the I/O device 22 may alsoinclude one or more locking features 92, which may be configured toblock the latch mechanism 88 that includes a push-push latch fromejecting the terminal block 30 from the base 28. Specifically, thelocking feature 92 may block ejection of the terminal block 30 when in alocked position and enable ejection of the terminal block 30 when in anunlocked position. In one embodiment, the locking feature 92 may becoupled to the base 28 at a hinge 94, which enables the locking feature92 to rotate away from the terminal block 30 in a direction 98 andtoward the terminal block 30 in a direction 99. For example, whencoupling the terminal block 30 to the base 28, the terminal block 30 ismoved in a direction 96 toward the base 28 and the locking feature 92may be rotated in the direction 98 to prevent the locking feature 92from interfering with the coupling of the terminal block 30. Theposition of the locking feature 92 rotated in the direction 98 shown inFIG. 5 may correspond to the unlocked position. After the terminal block30 is coupled to the base, the locking feature 92 may be rotated in thedirection 99 to block the latch mechanism 88 from ejecting the terminalblock 30 when inadvertently toggled. Specifically, an extension 93 ofthe locking feature 92 may interfere with movement of the terminal block30 in a direction 97 away from the base 28. The extension 93 may be acantilevered portion of the locking feature 92 or any similar hook,catch, or restraint. When uncoupling the terminal block 30 from the base28, the locking feature 92 may be rotated in the direction 98 and theterminal block 30 moved in the direction 97 away from base 28. In otherembodiments, the hinge 94 may be omitted and the locking feature 92coupled directly to the base 28. In such embodiments, the lockingfeature 92 may be made from a flexible material, such as plastic. Whenthe terminal block 30 is moved in the direction 96, the terminal block30 may push the locking feature 92 in the direction 98 to enablecoupling of the terminal block 30 to the base 28. Once the terminalblock 30 is coupled to the base, the locking feature 92 may move back inthe direction 99 to block the removal of the terminal block 30. Thelocking feature 92 may later be pushed in the direction 98 to enable theterminal block 30 to be removed.

FIG. 6 is a side cross-sectional view of the I/O device 22 in accordancewith embodiments of the present techniques. As illustrated, the terminalblock 30 is adjacent to the base 28. Specifically, the terminal blockconnectors 40 are engaged with the terminal block connector openings 42.In addition, the terminal block 30 rests against the top surface 87 ofthe base 28. In other words, the terminal block 30 is pushed completelyagainst the base 28 as the biasing element 90 is compressed. Thus, theterminal block connectors 40 are completely inserted into the terminalblock connector openings 42, thereby releasably engaging the terminalblock 30 with the base 28. When the latch mechanism 88 includes apush-push latch, the movement of the terminal block 30 toward the base28 in the direction 96 may correspond to the first step of engaging theterminal block with the base 28. In addition, as shown in FIG. 6, theterminal block 30 has moved the plunger 84 of the ejection device 80 inthe direction 96, thereby compressing the spring 90. Moreover, internallatches or cams of the latch mechanism 88 may be engaged by the firststep to cause movement of the terminal block in the direction 97, asdescribed in detail below. As shown in FIG. 6, the locking features 92are rotated toward the terminal block 30 in the direction 99 using thehinges 94. Thus, the extensions 93 of the locking features 92 may blockthe terminal block 30 from being ejected from the base 28. The positionof the locking feature 92 rotated in the direction 99 shown in FIG. 6may correspond to the locked position.

FIG. 7 is a side cross-sectional view of the I/O device 22 with theterminal block 30 coupled to the base 28 in accordance with embodimentsof the present techniques. After the first step of pushing the terminalblock 30 against the base 28, the ejection device 80 may push theterminal block 30 away from the base 28 by a distance 100, which maycorrespond to the length of the exposed portion 86 of the plunger 84.Specifically, the spring 90 may help push the latch mechanism 88 and theplunger 84 in the direction 97 against the terminal block 30. Thus, atop surface 102 of the terminal block 30 may be pushed adjacent theextensions 93 of the locking features 92. In other embodiments, the topsurface 102 may not be adjacent the extensions 93 when the latchmechanism 88 pushes against the terminal block 30. In other words, a gapmay exist between the top surface 102 and the extensions 93. As shown inFIG. 7, the terminal block connectors 40 are still coupled to theterminal block connector openings 42, thereby providing an electricalconnection between the terminal block 30 and the base 28. Theconfiguration of the terminal block 30, ejection device 80, and base 38shown in FIG. 7 may correspond to a normal position of the terminalblock 30. When the latch mechanism 88 includes a push-push latch, themovement of the terminal block 30 toward the base 28 in the direction 96a second time may correspond to the second step of ejecting the terminalblock 30 away from the base 28, provided that the locking features 92are not engaged. The second step follows the first step. The force usedto eject the terminal block 30 from the base 28 may be provided by thespring 90. As described above, by engaging the locking features 92,inadvertent ejection of the terminal block 30 may be avoided. Thus, whenthe latch mechanism 88 includes the push-push-latch, its use involvesmovement of the terminal block 30 in the direction 96. During the firststep, the terminal block 30 is engaged with the base 28 and is leftseparated from the base 30 by the distance 100. During the second step,the terminal block 30 is ejected from the base 28, provided that thelocking features 92 are not engaged. In other embodiments, other latchmechanisms 88 may be used instead of the push-push latch to eject theterminal block 30 from the base 28. In addition, in further embodiments,the ejection device 80 may be disposed in the terminal block 30 insteadof the base 28.

FIG. 8 is a side cross-sectional view of an exemplary I/O device 22 withthe terminal block 30 coupled to the base 28 in accordance withembodiments of the present techniques. As illustrated, the ejectiondevice 80 is lever-activated and configured to be used to eject theterminal block 30 from the base 28. Specifically, the ejection device 80includes an activation mechanism 112 to eject the terminal block 30 whenthe activation mechanism 112 is activated. As shown in FIG. 8, incertain embodiments, the activation mechanism 112 may be a lever. Inother embodiments, the activation mechanism 112 may be a button, switch,knob, dial, or any combination thereof. The activation mechanism 112enables a person to eject the terminal block 30. Specifically, in theillustrated embodiment, a person may push down on the activationmechanism 112 in the direction 96 to eject the terminal block 30 in thedirection 97. In the illustrated embodiment, the ejection device 80includes a first hinge 114, which may enable movement of the activationmechanism 112 in the direction 96. In addition, the ejection device 80may include a second hinge 116, which may be coupled to an ejector 118.The second hinge 116 may be configured to enable the ejector 118 to movewith respect to the activation mechanism 112. The ejector 118 may beconfigured to rise out of the base 28 through a passage 120 when theactivation mechanism 112 is pushed in the direction 96. In certainembodiments, the base 28 may include a cover 122, which may block accessto the ejection device 80. The cover 122 may be coupled to the base 28via a hinge 124, which may enable the cover 122 to rotate away from theejection device 80 in the direction 96 when access to the ejectiondevice 80 is desired. Thus, when the cover 122 is rotated in thedirection 97, the cover 122 may help prevent inadvertent ejection of theterminal block 30 via the ejection device 80. In certain embodiments,the cover 122 may be removable or omitted entirely. In furtherembodiments, the activation mechanism 112 may be biased with the ejector118 in a deployed or retracted position when no terminal block 30 iscoupled to the base 28. For example, a spring or similar device may beused to bias the ejector 118 in a position. In addition, although shownbeing used with the terminal block 30 in FIG. 8, in other embodiments,the ejection device 80 may also be used with the module 32.

FIG. 9 is a side cross-sectional view of the I/O device 22 with theterminal block 30 positioned above the base 28 in accordance withembodiments of the present techniques. As illustrated in FIG. 9, theejection device 80, including a lever-activated mechanism, has been usedto eject the terminal block 30 from the base 28 in the direction 97.Specifically, the cover 122 has been rotated away from the ejectiondevice 80 in the direction 96 to enable a person to access theactivation mechanism 112. As shown, the activation mechanism 112 hasbeen pushed downward in the direction 96, thereby lifting the ejector118 in the direction 97 against the terminal block 30. Thus, the ejector118 has pushed the terminal block 30 away from the base 28 by thedistance 100, which may indirectly correspond to a length of the ejector118. As shown in FIG. 9, the terminal block connectors 40 are no longerconnected to the terminal block connector openings 42. Thus, theterminal block 30 is not electrically connected to the base 28. Infurther embodiments, other mechanisms similar to the ejection device 80may be used to eject the terminal block 30 from the base 28. Inaddition, the ejection device 80 may be disposed in the terminal block30 instead of the base 28. Although the activation mechanism 112 isshown moving only in the linear directions 96 and 97 in FIGS. 8 and 9,in other embodiments, the activation mechanism 112 may move in a lineardirection, a rotary direction, a curved direction, or any combinationthereof.

FIG. 10 is a side cross-sectional view of an exemplary I/O device 22with the locking mechanism 140 in an unlocked position in accordancewith embodiments of the present techniques. As illustrated, the lockingmechanism 140 uses the latch 66 to help secure the terminal block 30 tothe module 32. Specifically, the latch 66 may include an extension 67that engages with the module 32 when the latch is moved in a direction164, as described in detail below. In addition, the locking mechanism140 may be used to electrically connect the terminal block 30 to themodule 32 or to complete a circuit.

Specifically, the terminal block 30 includes a hinge 142 that includes aconducting portion 144. For example, in certain embodiments, the hinge142 may be made from a non-conducting material, such as plastic. Theconducting portion 144 may be made from a conducting material, such as ametal. The terminal block 30 may include a connector 146 adjacent to thehinge 142. The connector 146 may be made from a conductive material,such as a metal. A wire 148 may be connected to the connector 146.Similarly, the module 32 may include a connector 150 adjacent to thehinge 142 and a wire 152 connected to the connector 150.

Further, the terminal block 30 may include a power circuit 154 and/or aground circuit 156. The power circuit 154 may provide electrical powerto the terminal block 30 and the ground circuit 156 may provide a groundpath for the terminal block 30. One or more wires 148 may be used toconnect the connector 146 to the power circuit 154 and/or the groundcircuit 156. Similarly, the module 32 may include a power circuit 158and a ground circuit 160. One or more wires 152 may be connected to thepower circuit 158 and/or the ground circuit 160. Further, a ground wire162 may be used to connect the ground circuit 160 of the module 32 tothe DIN rail 26, which may be connected to a ground. Similarly, theground wire 162 may be used to connect the ground circuit 156 of theterminal block 30 to the DIN rail 26.

As shown in FIG. 10, the latch 66 is positioned away from the module 32such that the conductive portion 144 is not aligned with the connectors146 and 152. Thus, when the latch 66 is rotated away from the module 32,the terminal block 30 is not electrically connected to the module 32. Inaddition, when the latch is rotated away from the module 32, either theterminal block 30 or the module 32 may be removed from the base 28. Inaddition, although shown integral with the terminal block 30 in FIG. 10,in other embodiments, the locking mechanism 140 may be integral with themodule 32. For example, the locking mechanism 140 may be used toelectrically connect the module 32 to the terminal block 30.

FIG. 11 is a side cross-sectional view of the I/O device 22 with thelocking mechanism 140 in a locked position in accordance withembodiments of the present techniques. As illustrated, the latch 66 hasbeen rotated in the direction 164 against the module 32. Specifically,the extension 67 of the latch 66 may block removal of the module 32 fromthe base 28. The extension 67 may be a cantilevered portion of the latch66 or any similar hook, catch, or restraint. In addition, in certainembodiments, the extension 67 may engage with a tab, notch, or similarconnecting feature on the module 32 to help block removal of theterminal block 30 from the base 28. In other words, after the extension67 has engaged with the connecting feature of the module 32, additionalforce may be required to move the latch 66 in the direction 165. Asshown in FIG. 11, the conducting portion 144 is aligned with theconnectors 146 and 150, thereby electrically connecting the terminalblock 30 to the module 32. Thus, the power circuit 154 may beelectrically connected to the power circuit 158. Similarly, the groundcircuit 156 may be electrically connected to the ground circuit 160. Inother embodiments, different circuits may be completed or broken bymovement of the latch 66. Thus, the locking mechanism 140 may act toboth lock the terminal block 30 and/or the module 32, and electricallyconnect the terminal block 30 to the module 32 when placed in the lockedposition shown in FIG. 11. To electrically disconnect the terminal block30 from the module 32, the latch 66 may be moved in the direction 165away from the module 32, corresponding to the unlocked position shown inFIG. 10. In the unlocked position shown in FIG. 10, the module 32 and/orthe terminal block 30 may be removed from the base 28. In otherembodiments, other mechanisms similar to the locking mechanism 140 maybe used to restrain the terminal block 30 and provide for electricalconnection and disconnection from the module 32.

FIG. 12 is a side cross-sectional view of an exemplary I/O device 22with the locking mechanism 140 configured to rotate in accordance withembodiments of the present techniques. As shown, the locking mechanism140 is used to secure the terminal block 30 and/or the module 32 to thebase 28. The locking mechanism 140 includes a grip 182, which may beused by a person to lock or unlock the locking mechanism 140 by rotatingthe locking mechanism about an axis 190. The grip 182 may be coupled toa shaft 184, which may be placed between the terminal block 30 and themodule 32. In other embodiments, the shaft 184 may be integral with theterminal block 30 and/or the module 32. In certain embodiments, theshaft 184 includes a locking portion 186, which may be used to securethe terminal block 30 and/or the module 32 in a locked position.Specifically, the locking portion 186 may engage with the terminal block30 and/or the module 32 when in the locked position. The lockingmechanism 140 may include a rotating base 188 disposed in the base 28.The rotating base 188 may include bearings or a similar device to enablethe locking mechanism 140 to rotate about the axis 190. As described indetail below, the locking mechanism 140 may also be used to electricallyconnect the terminal block 30 and the module 32.

FIG. 13 is cross-sectional view along the line labeled 12-12 in FIG. 12of an embodiment of the locking mechanism 140 in an electricallyconducting position. As shown in FIG. 13, a diameter 192 of the shaft184 may be less than a diameter 194 of the locking portion 186. Inaddition, the locking portion 186 may include one or more conductingportions 144, which may be configured to electrically connect with theconnectors 146 and/or 150. For example, when the conducting portions 144are aligned with both the connectors 146 and 150, the power circuits 154and 158 of the terminal block 30 and the module 32 may be electricallyconnected to one another. In other embodiments, when the conductingportions 144 are aligned with both the connectors 146 and 150, theground circuits 156 and 160 may be electrically connected to oneanother. Thus, the position of the locking portion 186 in FIG. 13corresponds to an electrically connected configuration of the terminalblock 30 and module 32. In certain embodiments, the conducting portions144 may also lock the terminal block 30 and the module 32 to the base28. In other words, the conducting portions 144 may block removal of theterminal block 30 and the module 32. In other embodiments, the lockingmechanism 140 may include locking devices 196, such as tabs, extensions,notches, or similar mechanisms, that are separate from the conductingportions 144 to lock the terminal block 30 and the module 32 to the base28. For example, in the illustrated embodiment of FIG. 13, the lockingmechanism 140 includes two conducting portions 144 and one lockingdevice 196 arranged in a T-shaped configuration. Specifically, thelocking device 196 is located in between the two conducting portions144. As shown in FIG. 13, the two conducting portions 144 are alignedwith the connectors 146 and 150 to electrically connect the terminalblock 30 and the module 32, and to physically block removal of both theterminal block 30 and the module 32. The locking device 196 is used toblock removal of only one of the terminal block 30 and the module 32, asdescribed in detail below. In further embodiments, different numbersand/or arrangements of the conducting portions 144 and the lockingdevices 196 may be used depending on the particular arrangement andrequirement of the I/O device 22.

FIG. 14 is a cross-sectional view along the line labeled 12-12 in FIG.12 of the locking mechanism 140 in an electrically unconnectedconfiguration. As shown in FIG. 14, the locking mechanism 140 is rotated90 degrees in the direction 196 with respect to the electricallyconnected configuration shown in FIG. 13. Thus, the two conductingportions 144 are not aligned with the connectors 146 and 150. Instead,the locking device 196 is aligned with the connector 150 of the module32. No conducting portion 144 or locking device 196 is aligned with theconnector 146 of the terminal block 30. Thus, the terminal block 30 andthe module 32 are not electrically connected to one another. In otherwords, FIG. 14 represents the electrically unconnected configuration ofthe locking mechanism 140. In addition, the terminal block 30 may beremoved from the base 28 because no conducting portion 144 or lockingdevice 196 is blocking removal of the terminal block 30. In addition,with the locking mechanism 140 in the electrically unconnectedconfiguration, the terminal block 30 may be coupled to the base 28 ifnot already present. However, the locking device 196 is aligned with theconnector 150, thereby blocking removal of the module 32 from the base28. After the terminal block 30 is removed from the base 28, the lockingmechanism 140 may be rotated 180 degrees such that no conducting portion144 or locking device 196 is aligned with the connector 150. Thus, themodule 32 may be removed from the base 28 or inserted if no module 32was already present. In other words, the locking mechanism 140 may beused to both lock the terminal block 30 and/or the module 32 to the base28, and to electrically connect the terminal block 30 to the module 32.Further, the configuration of the locking mechanism 140 with twoconducting portions 144 and one locking device 196 shown in FIG. 14 maybe used to selectively remove or lock the terminal block 30 and themodule 32 one at a time. In certain embodiments, the locking device 196may be omitted to enable the terminal block 30 and the module 32 to beremoved or locked simultaneously. In other embodiments, otherconfiguration and motions of the locking mechanism 140 may be used tocouple the terminal block 30 and/or the module 32 to the base 28, and toelectrically connect the terminal block 30 to the module 32.

FIG. 15 is a flow chart of a process 210 for operating the ejectiondevice 80 of the I/O device 22 in accordance with an embodiment of thepresent technique. In a first step 212, a component of the I/O device22, such as the terminal block 30 or the module 32, is moved toward thebase 28 in a first movement. In a second step 214, the component coupleswith the base 28. For example, the terminal block connectors 40 of theterminal block 30 may be inserted into the terminal block connectoropenings 42 of the base 28. In a third step 216, the component engageswith the ejection device 80, which may be disposed in the base 28. Incertain embodiments, the third step 216 may occur simultaneously withthe second step 214. In a fourth step 218, the ejection device 80 isactivated. For example, the component may be moved toward the base 28 ina second movement to activate the latch mechanism 88 when configuredwith a push-push latch. In other embodiments, the activation mechanism112 may be pushed to activate the ejection device 80. In a fifth step220, the component is moved away from the base 28 using the ejectiondevice 80. For example, the biasing element 90 of the ejection devicemay push the component out of engagement with the base 28 using theplunger 84 of the ejection device 80. In other embodiments, the ejector118 may push the component away from the base 28 as the activationmechanism 112 is pushed. In further embodiments, locking features 92and/or locking mechanisms 140 may be used to block the component frombeing disengaged from the base 28. In some embodiments, the lockingmechanism 140 may include conducting portions 144 to enable the terminalblock 30 to be electrically connected to the module 32 and/or the basewhen the locking mechanism 140 is in the locked position. Use of thevarious techniques described above may facilitate removal of thecomponent from the base and/or help block inadvertent removal of thecomponent from the base.

While only certain features of the invention have been illustrated anddescribed herein, many modifications and changes will occur to thoseskilled in the art. For example, while locking and ejection features areillustrated on specific components of an I/O device in the figuresdescribed above, in other embodiments, such features may be incorporatedwith other or additional components of an I/O device. It is, therefore,to be understood that the appended claims are intended to cover all suchmodifications and changes as fall within the true spirit of theinvention.

The invention claimed is:
 1. An input/output (I/O) device for anautomation control system, the I/O device comprising: a base portioncomprising at least a first mating feature of the base portion and asecond mating feature of the base portion; an I/O module configured tophysically and communicatively couple with the base portion via couplingof a mating feature of the I/O module with the first mating feature ofthe base portion, wherein the I/O module comprises I/O communicationcircuitry; a terminal block configured to physically and communicativelyconnect to the base portion via coupling of a mating feature of theterminal block with the second mating feature of the base portion; andan ejection device configured to eject the I/O module or the terminalblock from the base portion by pushing the mating feature of the I/Omodule out of the first mating feature of the base portion or the matingfeature of the terminal block out of engagement with the second matingfeature of the base portion as a mechanical response to actuation of anactivation mechanism of the ejection device.
 2. The I/O device of claim1, wherein the base portion comprises a receptacle for communicativelycoupling the base portion with a DIN rail and wherein the base portionoperates to provide a communication path between the terminal block andthe I/O module.
 3. The I/O device of claim 1, wherein the ejectiondevice is integral with the I/O module, terminal block, or the baseportion.
 4. The I/O device of claim 1, wherein the activation mechanismis configured to be actuated in a linear direction, a rotary direction,a curved direction, or a combination thereof.
 5. The I/O device of claim1, wherein the ejection device comprises a lever and an ejector, thelever being coupled to the base portion, I/O module, or terminal blockvia a first hinge and being coupled to the ejector via a second hinge,wherein a portion of the lever extends from the base portion, I/Omodule, or terminal block to form the activation mechanism such thatactuation of the activation mechanism causes the lever to move about thefirst hinge, which causes the ejector to move relative to the baseportion, I/O module, or terminal block about the second hinge.
 6. TheI/O device of claim 1, comprising a cover configured to block access tothe activation mechanism when the cover is closed.
 7. The I/O device ofclaim 6, wherein the cover is coupled to the base portion, I/O module,or terminal via cover hinge.
 8. The I/O device of claim 1, wherein theejection device is biased into a default position by a biasingmechanism.
 9. The I/O device of claim 1, wherein the ejection devicecomprises a curved lever coupled to the base portion, I/O module, orterminal block via a hinge.
 10. The I/O device of claim 1, wherein thefirst mating feature of the base portion comprises a female matingfeature and the mating feature of the I/O module comprises a male matingfeature, wherein the ejection device is configured to eject the I/Omodule from the base portion by pushing against the male mating feature.11. The I/O device of claim 1, wherein the second mating feature of thebase portion comprises a female mating feature and the mating feature ofthe terminal block comprises a male mating feature, wherein the ejectiondevice is configured to eject the terminal block from the base portionby pushing against the male mating feature.
 12. A component of aninput/output (I/O) device, the component comprising: a first connectorconfigured to engage with a second connector of an additional componentof the I/O device; and an ejection device configured to eject theadditional component from the component by pushing the second connectoraway from the first connector, wherein the ejection device comprises: anactivation portion extending outside of the component and configured tobe physically actuated; and an ejector portion configured to contact anyapply force against the additional component as a mechanical response tophysical actuation of the activation portion.
 13. The component of claim12, wherein the ejection device comprises a curved lever coupled withthe component via a hinge.
 14. The component of claim 12, wherein theejector portion is configured to slide along a path formed in a body ofthe component.
 15. The component of claim 12, wherein the activationportion comprises a lever coupled to the component via a first hinge andwherein the ejector portion is coupled to the lever by a second hingesuch that movement of the lever in a first direction about the firsthinge causes the ejector portion to move in a second direction about thesecond hinge, wherein the first direction is opposite the seconddirection.
 16. The component of claim 12, comprising a cover configuredto block access to the activation portion when the cover is closed. 17.The component of claim 12, comprising a latch configured to couple thecomponent with the additional component or another component, whereinthe latch includes a conducting portion configured to provide acommunicative coupling between a circuit of the component and a separatecircuit of the additional component or the another component when thelatch is coupling the component with the additional component or theanother component.
 18. An input/output (I/O) device for an automationcontrol system, the I/O device comprising: a base portion comprising atleast a first mating feature of the base portion and a second matingfeature of the base portion; an I/O module configured to physically andcommunicatively couple with the base portion via coupling of a matingfeature of the I/O module with the first mating feature of the baseportion, wherein the I/O module comprises I/O communication circuitry; aterminal block configured to physically and communicatively connect tothe base portion via coupling of a mating feature of the terminal blockwith the second mating feature of the base portion; and a lockingmechanism configured to couple together the I/O module and the terminalblock when in a closed orientation, wherein the locking mechanismcomprises a conducting portion configured to communicatively couplecircuitry in the I/O module with circuitry in the terminal block whenthe locking mechanism is in the closed orientation.
 19. The I/O deviceof 18, wherein the locking feature is configured to be engaged by movingthe locking feature in a linear direction, a rotary direction, a curveddirection, or a combination thereof.
 20. The I/O device of claim 18,wherein the locking mechanism comprises a latch configured to be rotatedabout a hinge, wherein the conducting portion comprises a linearconductor disposed within and extending through the hinge.
 21. The I/Odevice of claim 18, wherein the locking mechanism comprises a shaftconfigured to extend along the base portion, the I/O module, and theterminal block to facilitate locking the base portion, the I/O moduleand the terminal block together when in the closed orientation.
 22. TheI/O device of claim 18, wherein the circuitry in the I/O module and thecircuitry in the terminal block comprise power and ground circuitry.